On-site processing of scrap drywall for facilitating removal, transportation, and recycling

Abstract

Methods and systems for processing and recycling drywall are described herein. A mobile dry wall processor may be used at a construction site to process or crush scrap or waste drywall to reduce the size of dry wall pieces before transporting the drywall off the construction site. The mobile drywall processor may include a container to capture the processed drywall. The container and the mobile drywall processor may be configured in size and shape for easy transportation to and from construction sites, including building interiors. Processed drywall is transported to be recycled or to a landfill. The processed or crushed drywall may have a higher density, reducing shipping and transportation costs.

What is claimed is: 
     
         1 . A drywall processor device comprising:
 a base configured to receive a container that receives drywall that has been processed by the drywall processor device, the base further comprising a plurality of wheels that facilitate movement of the drywall processor device; and   a drywall crusher assembly coupled to and supported by the base, the drywall crusher assembly comprising:
 a feed chute comprising an opening configured to receive pieces of scrap drywall to be processed by the drywall processor device, the feed chute extending along a vertical axis; 
 an electric motor; 
 a drive shaft configured to be rotatably driven by the electric motor; and 
 one or more hammers fixedly coupled to the drive shaft such that the hammers rotate with the drive shaft when driven by the electric motors, the one or more hammers positioned such that, during at least a portion of the rotation of the drive shaft, the one or more hammers pass below an outlet of the feed chute so as that the one or more hammers contact the pieces of scrap drywall received at the feed chute to break the pieces of scrap drywall into smaller pieces, thereby reducing a bulk volume of the pieces of scrap drywall. 
   
     
     
         2 . The drywall processor device of  claim 1 , wherein an overall width of the device is less than 36 inches so that the drywall processor device can fit through a door frame. 
     
     
         3 . The drywall processor device of  claim 1 , wherein the opening of the feed chute is rectangular in shape having a width less than 3 inches. 
     
     
         4 . The drywall processor device of  claim 1 , wherein the one or more hammers are positioned at a vertical level no more than 6 inches below an outlet of the feed chute. 
     
     
         5 . The drywall processor device of  claim 1 , wherein the one or more hammers comprise four hammers extending radially outward from the drive shaft at 90-degree offsets with respect to each other. 
     
     
         6 . The drywall processor device of  claim 1 , wherein the electric motor is configured to operate using 120-volt AC. 
     
     
         7 . The drywall processor device of  claim 1 , wherein the electric motor comprises an output shaft that is rotationally coupled to the drive shaft through a belt and one or more pulleys. 
     
     
         8 . The drywall processor device of  claim 1 , wherein the base comprises an enclosure accessible through a door, and wherein the container is configured to be received within the door. 
     
     
         9 . The drywall processor device of  claim 1 , wherein the container is a 32-gallon trash can. 
     
     
         10 . wall processor device of  claim 1 , further comprising at least one sensor configured to detect a fill level of the container, and at least one indicator for indicating that the container is filled based on an output of the at least one sensor. 
     
     
         11 . The drywall processor device of  claim 1 , wherein the drywall processor device is configured to reduce the bulk volume of the pieces of scrap drywall by at least 20%. 
     
     
         12 . The drywall processor device of  claim 1 , wherein the drywall processor device is configured for transport to and use at a jobsite. 
     
     
         13 . A method for processing scrap drywall at a jobsite, the method comprising:
 providing a drywall processor device at the jobsite, wherein the drywall processor device is configured to crush scrap drywall thereby reducing a bulk volume of the scrap drywall;   feeding pieces of scrap drywall into the drywall processor device at the jobsite, whereby the drywall processor devices crushes the pieces of scrap drywall and collects processed scrap drywall in a container;   collecting the processed scrap drywall; and   transporting the processed scrap drywall from the jobsite.   
     
     
         14 . The method of  claim 13 , wherein transporting the processed scrap drywall from the jobsite comprises transporting the processed scrap drywall directly to a disposal facility or a recycling facility. 
     
     
         15 . The method of  claim 13 , wherein the processed scrap drywall is transported using trucks that deliver construction materials to the jobsite. 
     
     
         16 . The method of  claim 13 , further comprising:
 preprocessing the pieces of scrap drywall by manually cutting or breaking the pieces to a size that fits within a feed chute of the drywall processor device.   
     
     
         17 . The method of  claim 13 , wherein providing the drywall processor device at the jobsite comprises moving the drywall processor device through one or more doors or up or down one or more elevators. 
     
     
         18 . The method of  claim 13 , wherein the drywall processor device comprises:
 a base configured to receive a container that receives drywall that has been processed by the drywall processor device, the base further comprising a plurality of wheels that facilitate movement of the drywall processor device; and   a drywall crusher assembly coupled to and supported by the base, the drywall crusher assembly comprising:
 a feed chute comprising an opening configured to receive pieces of scrap drywall to be processed by the drywall processor device, the feed chute extending along a vertical axis; 
 an electric motor; 
 a drive shaft configured to be rotatably driven by the electric motor; and 
 one or more hammers fixedly coupled to the drive shaft such that the hammers rotate with the drive shaft when driven by the electric motors, the one or more hammers positioned such that, during at least a portion of the rotation of the drive shaft, the one or more hammers pass below an outlet of the feed chute so as that the one or more hammers contact the pieces of scrap drywall received at the feed chute to break the pieces of scrap drywall into smaller pieces, thereby reducing the bulk volume of the pieces of scrap drywall. 
   
     
     
         19 . The method of  claim 18 , wherein an overall width of the drywall processor device is less than 36 inches so that the drywall processor device can fit through a door frame. 
     
     
         20 . The method of  claim 13 , wherein the bulk volume of the scrap drywall is reduced by at least 20%.